NTPC Kahalgaon is a 2340 MW coal-based thermal power plant located in Bihar, India. It uses water tube boilers fueled by coal from local mines to produce superheated steam that drives turbines to generate electricity. Ash produced from burning coal is disposed of in ash dykes, which are engineered embankments that contain the ash slurry. The plant also has a coal handling plant to receive, crush, and transport coal, as well as a water treatment system and cooling towers to manage water usage. The industrial training report provides an overview of the key components and processes at the NTPC Kahalgaon power plant.

1. INDUSTRIAL TRAINING REPORT
SUBMITTED TO:- SUBMITTED BY:
Prof. R K Mathur sir Ankesh kumar
NTPC KAHALGAON Roll No-CE/14/17
B.Tech(Civil engg.)
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2. LIST OF CONTENT:
1. About NTPC
2. NTPC Kahalgaon
3. Coal handling plant (CHP)
4. Boiler
5. Ash dyke
6. Merry Go Round (MGR)
7. Water Treatment & Cooling tower
8. Advantages and disadvantages of coal based thermal
power plant
9. Conclusion
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3. ABOUT NTPC:
 NTPC (National Thermal Power Corporation) is largest
Indian state owned electric utility company.
 It is an Indian central Public Sector Undertaking (PSU)
under the Ministry of Power, Government of India.
 It was founded by government of India in 1975.
 It is the largest power company in India with an electric
power generating capacity of 45,548 MW.
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4. NTPC KAHALGAON:
 Approved capacity -2340 MW
 Installed capacity -2340 MW
 Location -kahalgaon, Bihar
 Water source -river Ganga
 Fuel -coal
 Source of fuel -rajmahal, murra, lalmatia coal
field of eastern coalfield limited.
 Unit size -Stage I : 4* 210 MW and
Stage II: 3* 500 MW
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5. COAL HANDLING PLANT (CHP):
 14.3 M tonne of coal is consumed by plant per year.
 Coal reaches the CHP through train.
 The coal is placed in Track Hopper.
 From track hopper through conveyor belts coal reaches the
crusher home (coal is crushed to a size <20mm)
 In between track hopper and crusher house Suspended
magnets, Magnetic detector and magnetic separators are
placed to remove heavy metal pieces.
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7. BOILER:
 It is a closed vessel in which steam is generated by means
of heat energy.
 Water tube boilers are used in Stage I and Stage II.
 Water tube boiler are the one in which water circulates in
tubes which are heated externally by fire.
 Water tube boilers are used for high pressure boilers.
 Super heated steam is used in driving turbines (steam
heated to temp.~390℃).
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8. ASH HANDLING DEPARTMENT
WHAT IS ASH ?
Ash is the residue remaining after the coal has been
incinerated to constant weight under standard
conditions.
 Ash is oxidised form of the mineral matters present in
coal.
 Typical ash composition : SiO2, Al2O3, Fe2O3,
CaO,MgO etc.
 Coal with more SiO2 & Al2O3, Ash MP > 1400ºC
 Coal with more Fe2O3, CaO & MgO, Ash MP < 1100ºC
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9. WHY ASH HANDLING?
 Ash content of Indian coal used in power station is
about 30 to 40 %.
 A typical 2000 MW station produce around 9000T
to 12000T of ash per day.
 This huge amount of ash needs to be disposed off
continuously.
 Necessary care to be taken for preventing pollution
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10. ASH-DYKE:
 It is an engineered structure for the disposal of bottom
ash and fly ash.
 Disposal methods-wet disposal and dry disposal.
 Wet disposal is preferred due to economy.
 In wet method fly ash slurry is filled in large ponds
allowing the water to drain and evaporate.
 Ash ponds are generally ring embankments to enclose
the disposal site.
 The design primarily focuses on handling seepage and
ensuring slope stability.
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12. MERRY GO ROUND (MGR)
 MGR is a block train of hopper wagons which loads and unloads
its cargo while moving.
 These trains were introduced in the 1960’s in United Kingdom.
 MGR is a closed circuit dedicated rail transportation system
between the production and consumption points.
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14. OFF-SITE DEPARTMENT
 Water Treatment
 Cooling Tower
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15. Why water treatment?
 Raw water contains many dissolved minerals and organic
materials.
 At high temperature certain minerals left scaling on the
tube metal of the boiler and cause permanent damage.
 Some dissolved minerals leads to corrosion of tube metals.
Some leads to foaming
 At high pressure and temperature an element, silica can be
carried away with steam causing damage to turbine low
pressure stage.
 A Thermal Power Station needs water of varying quality for
different process and hence the requirement.
 The performance and life expectancy of the station greatly
depends on water chemistry compliance.
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16. Type of water treatment
 the type of demineralization process chosen for a
power
 station depends on three main factors :
1.The quality of the raw water.
2.The degree of deionisation i.e. treated water quality
3.Selectivity of resins.
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17. Steps of treatment process
 Aeration of raw water
 Adding chemicals for bacteria removal
 Adding chemicals for sedimentation of suspended particles
 Flocculation
 Filtration
 Ion Exchange process
 water treatment process is generally made up of two
sections :
1.Pretreatment section
2.Demineralisation section
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18. COOLING TOWER:
 The cooling tower is a semi enclosed structure for
evaporative cooling of water by contact with air.
 The hot water from the condenser is fed to the top of
the tower and allowed to tickle in form of drops.
 The air flows from bottom of the tower and exhausts to
the atmosphere after effective cooling.
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21. ADVANTAGES OF COAL BASED
THERMAL POWER PLANT:
 They can respond changing loads without difficulty.
 Fuel used is cheaper.
 Cheaper in production cost in comparison with that of
diesel power station.
 Steam engines and turbines can work under 25% of
overload continuously.
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22. DISADVANTAGES OF COAL
BASED THERMAL POWER PLANT:
 Maintenance and operating costs are high.
 Long time required for erection and putting into
action.
 A large quantity of water is required.
 Great difficulty experienced in coal handling.
 Presence of troubles due to smoke and heat in the
plant.
 Unavailability of good quality coal.
 Problem of ash removing.
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23. CONCLUSION
Overall, I had a fantastic experience while training
with the engineers of NTPC .
I feel extremely fortunate to be a part of the
Maharatna company of India for a month. This
summer training helped me grow a lot and get a
deeper look into the various fields.
The summer training program in NTPC is unique
because of more exposure we get in the company.
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Thank You!!